Apparatus and method for use with automotive door handling process

ABSTRACT

An automobile door support apparatus including an apparatus support frame, and a door support frame connected to the apparatus support frame. The door support frame may be configured to contact an automobile door at predetermined locations. A support cable may be adjustably connected to the apparatus support frame, and a door support hook may be connected to the support cable. The door support hook may include a hook end and an cable end. The hook end may be configured to engage a predetermined area of the automobile door for securely supporting the automobile door on the automobile door support apparatus and disengage from the predetermined area to allow removal of the automobile door from the automobile door support apparatus.

RELATED APPLICATIONS

This application claims benefit of priority of Provisional Application Ser. No. 60/765,721, filed Feb. 7, 2006, hereby incorporated by reference in its entirety.

BACKGROUND OF INVENTION

a. Field of Invention

The invention relates generally to an apparatus and method for use in an automotive manufacturing and repair process, and, more particularly, to an apparatus for mounting and handling of automotive doors and other such components.

b. Description of Related Art

During the manufacture of automobiles, doors and other such components are generally installed onto an automobile in an assembly line process. After initial alignment and installation of an automobile door, ideally the door would not have to be removed. However, it is often necessary for doors and similar components to be periodically removed at different stages of the manufacturing process for installation of sub-components and/or application of treatments to the door itself. In a similar manner, repair of a door and/or repair of a door subcomponent often requires the removal of the door.

Due to the significant amount of weight and dimensions of a typical automobile door, it is often difficult for an individual person to remove, handle, align, and/or install a door. Additional persons and/or apparatus are thus required during such processes. In order to minimize the number of personnel needed for such operations, in some assembly or repair operations, an apparatus for supporting automobile doors and allowing work to be performed thereon may be provided. Known apparatus for supporting doors during their removal and repair have been problematic due to the potential for a door to be misaligned upon the apparatus. In an assembly line atmosphere, the misalignment and unpredictable positioning of a door upon a device can lead to inefficiency during such operations and can even be a source of danger to a user.

There are generally two types of known apparatus for supporting automotive doors during removal and repair operations. One such apparatus includes a series of clamping devices used to align and secure the door upon the apparatus. This apparatus is inefficient in use in that it requires the completion of multiple tasks by a user prior to the door being secured upon the apparatus. During the time where all of the clamps are being engaged, the door may fall from the apparatus causing damage to the door and/or potentially injure the user. Further, the multiple clamps cause variation in the points of contact with the door, increasing the potential for misalignment and/or inconsistent alignment upon the apparatus.

In another known apparatus, the door is placed on mounting beds. In this apparatus, the door is arranged onto the apparatus and is held practically upright between the mounting beds. The mounting beds are predetermined, static points of contact between the apparatus and the door. This type of apparatus has a tendency to cause damage to the door either at the points of contact, or by the door falling off the apparatus. Another drawback to the mounting bed apparatus is that the apparatus does not easily adapt to different size doors, and further, precision work is made difficult because the door is not secured, but it is merely held in place.

It is therefore desirable for an apparatus to allow a user to efficiently and consistently work upon a secured door. It is also desirable for the apparatus to be easy to use, without compromising how securely the door is supported, for the apparatus to be operable in a minimal number of steps for securing a door, and for the apparatus to be capable of securing a door without damage.

SUMMARY OF THE INVENTION

The present invention overcomes the drawbacks and deficiencies of the aforementioned automotive door support apparatus by providing an automobile door support apparatus including an apparatus support frame, and a door support frame adjustably connected to the apparatus support frame. The door support frame may include first and second support members, and an underside support member connected to the first and second support members. An underside brace may be connected to the underside support member and configured to support an underside of an automobile door. A cable rod may be provided and include first and a second ends. The first end may be configured to receive and maintain a support cable in a predetermined orientation and the second end may be adjustably connected to either the apparatus support frame or the door support frame. The support cable may include first and second ends. The first end of the support cable may be connected to a cable tension lever adjustably connected to the apparatus support frame for applying tension to the support cable and the second end of the support cable may include a door support hook connected thereto. The door support hook may be configured to removably engage a predetermined area of an automobile door. Actuation of the cable tension lever may securely hold the automobile door via the support cable and the door support hook. An upper door support may be adjustably connected to the apparatus support frame for supporting and maintaining the automobile door. The automobile door support apparatus may thus support the automobile door in a predetermined position by contacting and supporting the door via the upper door support, the door support hook, and the underside brace.

For the apparatus described above, the apparatus may further include a cable guide adjustably attached to the apparatus support frame and configured to maintain the support cable in substantial alignment with the apparatus support frame. The upper door support may be rotatably connected to the apparatus support frame. The upper door support may further include a plurality of door guides configured to contact automobile doors of different configurations. In a particular embodiment, the cable tension lever may be a ratchet lever hoist.

The invention also provides an automobile door support apparatus including an apparatus support frame, and a door support frame connected to the apparatus support frame. The door support frame may be configured to contact an automobile door at predetermined locations. A support cable may be adjustably connected to either the apparatus support frame or the door support frame. A door support hook may be connected to the support cable and include a hook end and an cable end. The hook end may be configured to engage a predetermined area of the automobile door for securely supporting the automobile door on the automobile door support apparatus and disengage from the predetermined area to allow removal of the automobile door from the automobile door support apparatus.

For the apparatus described above, the apparatus may further include a cable rod adjustably attached to the apparatus support frame and having first and second ends. The first end of the cable rod may extend away from the apparatus support frame and be configured to guide the support cable. A tension means may be adjustably connected to the apparatus support frame and the support cable, and be configured to place the support cable and the door support hook in tension upon actuation thereof. The door support frame may further include an underside door support configured to support an underside of an automobile door. The apparatus may further include an upper door support adjustably attached to the door support frame, the upper door support being configured to contact an automobile door. In a particular embodiment, the apparatus support frame may be configured to attach to and travel upon a ceiling mounted assembly track. Alternatively, a tensioning lever may be adjustably connected to the apparatus support frame and the support cable, with the tension lever configured to place the support cable and the door support hook in tension upon actuation thereof.

The invention yet further provides a method for supporting an automobile door with an apparatus including an apparatus support frame, and a door support frame connected to the apparatus support frame. The door support frame may be configured to contact an automobile door at predetermined locations (i.e. at a preformed keyhole). A support cable may be adjustably connected to the apparatus support frame, and a door support hook may be connected to the support cable. The door support hook may include a hook end and an cable end. The method may include engaging the hook end to a predetermined area of the automobile door for securely supporting the automobile door on the automobile door support apparatus, and engaging a tensioning lever adjustably connected to the apparatus support frame and the support cable for placing the support cable and the door support hook in tension.

For the method described above, the method may further include adjusting a connection of the apparatus support frame and the door frame support to align the door frame support with an automobile door. The method may also include disengaging the door support hook from the predetermined area for removing the automobile door from the apparatus.

Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings:

FIG. 1 is an isometric view of an embodiment of an automobile door support apparatus according to the present invention, configured for use with a passenger side door;

FIG. 2 is a side view of a door support hook for use with the automobile door support apparatus of FIG. 1;

FIG. 3 is an isometric view of another embodiment of an automobile door support apparatus according to the present invention, configured for use with a passenger side door;

FIG. 4A is a front view of the automobile door support apparatus of FIG. 3, and FIG. 4B is an enlarged view of an upper door support;

FIG. 5 is a top view of the automobile door support apparatus of FIG. 3;

FIG. 6A is an enlarged partial side view of the automobile door support apparatus of FIG. 3, and FIG. 6B is a side view thereof;

FIG. 7 is a front view of another embodiment of an automobile door support apparatus according to the present invention, similar to the door support apparatus of FIG. 3, configured for use with a driver side door;

FIG. 8 is an enlarged front view of the automobile door support apparatus of FIG. 7, illustrating installation of a door support hook;

FIG. 9 is an enlarged front view of the automobile door support apparatus of FIG. 7, illustrating an upper door support;

FIG. 10 is an enlarged view of the automobile door support apparatus of FIG. 7, illustrating a tensioning hook;

FIG. 11 is an enlarged view of the automobile door support apparatus of FIG. 7, illustrating a cable rod;

FIG. 12 is an enlarged view of the automobile door support apparatus of FIG. 7, illustrating the door support hook of FIG. 8 in an installed configuration;

FIG. 13 is an enlarged view of the automobile door support apparatus of FIG. 7, illustrating the door support hook of FIG. 8 in an installed configuration;

FIG. 14 is an enlarged view of the automobile door support apparatus of FIG. 7, illustrating a vertical frame in which the cable rod of FIG. 11 slides;

FIG. 15 is an isometric view of another embodiment of an automobile door support apparatus according to the present invention, configured for use with a passenger side door;

FIG. 16A is a front view of the automobile door support apparatus of FIG. 15, and FIG. 16B is an enlarged view of an upper door support;

FIG. 17 is a top view of the automobile door support apparatus of FIG. 15;

FIG. 18A is an enlarged side view of the automobile door support apparatus of FIG. 15, and FIG. 18B is a side view thereof; and

FIG. 19 is an isometric view of another embodiment of an automobile door support apparatus according to the present invention, illustrating the use of dual cable rods.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring now to the drawings wherein like reference numerals designate corresponding parts throughout the several views, FIGS. 1 and 2 illustrate an embodiment of an automobile door support apparatus according to the present invention, generally designated “automobile door support apparatus 10,” and FIGS. 3-6B, 7-14, 15-18B and 19, respectively, illustrate additional embodiments of automobile door support apparatus 10.

Referring to FIG. 1, automobile door support apparatus 10 is illustrated as having a passenger door 90 positioned thereon. As illustrated in FIG. 7, those skilled in the art would readily appreciate in view of this disclosure that apparatus 10 may be configured as needed for use with a driver side door. Automobile door support apparatus 10 may generally include a vertical frame 12 disposed in a substantially vertical orientation and a door support frame 14 connected thereto in a fixed or adjustable manner. The adjustable connection may allow for vertical adjustment relative to the vertical frame. The adjustable connection may be implemented by a series of perforations 80 in vertical frame 12 (see FIGS. 18A and 18B). Door support frame 14 may be configured to securely fit into perforations at a desired vertical position (see also FIGS. 18A and 18B). Similarly, vertical frame 12 may include an elongated channel 78, and door support frame 14 may be configured to be slidably received and secured within the elongated channel 78 of vertical frame 12. In an embodiment where door support frame 14 is slidably received in elongated channel 78, the vertical position of the door support frame may be secured by the tightening of one or more positioning clamps 74, 76 and/or the tightening of screws.

Door support frame 14 may be configured to contact an automobile door 90, and may take a shape substantially similar to the periphery of an automobile door. Door support frame 14 may include first vertical support member 26, second vertical support member 28, and underside support member 30 therebetween. The rigid connection of the first vertical support member, underside support member, and second support member may define a shape similar to the periphery of an automobile door. In a particular embodiment, the door support member may include additional supports 32 and 34 (see FIG. 3). Support 32 may be a padded and/or solid cross bar configured to contact an automobile door, and support 34 may be a padded and/or solid bumper attached to second vertical support member 28, and may be configured to contact an automobile door without causing damage. Further, door support frame 14 may have underside door supports 36, 38, which may be configured to contact and support the underside of automobile door 90 without causing damage.

As shown in FIG. 1, an upper door support 40 may be adjustably connected upon door support frame 14 such that it can be moved to various vertical and horizontal positions. The vertical adjustments may be through clamping mechanisms and adjusting means similar to those allowing for the adjustable connection of door frame support 14 to vertical frame 12. The horizontal adjustments may be through a series of holes 72 and matching pins (not shown). The adjustments may be made to upper door support 40, allowing upper door support 40 to receive a variety of automobile doors. Alternatively, upper door support 40 may be set to consistently receive a specific automobile door, whereby automobile door support apparatus 10 may provide repeated, consistent support to one model of an automobile door. Upper door support 40 may include door grips 42, 44 and/or 46 (see FIGS. 1, 3 and 15) made of padded or solid material configured to provide lateral support to an automobile door placed into grips 42, 44 or 46. Upper door support 40 may include rotation handle 48 configured to rotate and lock door grips 42, 44 and 46 into position, allowing automobile door support apparatus 10 to secure automobile doors of different configurations. Rotation handle 48 may rotate and lock upper door support 40 into position through a series of pins and receiving keyholes. The pulling of rotation handle 48 may release pins from keyholes, allowing for rotation. Thereafter, rotation handle 48 may lock upper door support 40 into position by resetting the pins in desired keyholes.

As such, the automobile door support apparatus 10 may initially support an automobile door 90 with door support frame 14, including underside door supports 36, 38, upper door support 40 with door grips 42, 44 and 46, and additional supports 32 and/or 34.

Automobile door support apparatus 10 may secure automobile door 90 through the use of support cables 16 and 18. Support cables 16, 18 may be adjustably connected to vertical frame 12 via a hook, carabineer, similar attachment means, and/or directly attached to vertical frame 12. A tension means 50 may be provided as a latch that has a lever, which when engaged, applies tension to support cables 16, 18 connected thereon. Tension means 50 may further be a pulley system, winch, a ratchet lever hoist, and/or similar devices that may apply tension to a cable attached thereon.

Support cables 16 and 18 may be adjustably connected to tension means 50 via a hook, carabineer, similar attachment means, and/or being directly attached to the tension means 50. Support cable 16 and support cable 18 may be connected to door support hook 20, 21 having a hook end 22 and a cable end 24 (see FIG. 2). Generally, automobile doors are manufactured with certain keyholes on the side of the automobile door. Hook end 22 of door support hook 20 may be configured to engage and disengage from such manufactured keyholes on the side of an automobile door 90. Door support hook 20 may further include a contact bumper 23, allowing door support hook 20 to contact the door without causing damage to the automobile door. When door support hook 20 is engaged to the side of an automobile door, hook end 22 may contact the interior of the door. Concurrently, door support hook 20, and/or a contact bumper 23 thereon, contacts the exterior of the door. Hook end 22 contacting the interior of the door may provide an equal and opposite force to door support hook 20 contacting the exterior of the door. Thereby, door support hook 20 may be easily engaged to an automobile door 90 for securely maintaining contact with automobile door 90.

Automobile door support apparatus 10, which initially supports an automobile door 90 with door support frame 14, secures an automobile door 90 via engagement of door support hook 20 and utilization of tension means 50, which causes support cables 16 and 18 to be pulled taught therebetween.

Automobile door support apparatus 10 may further include one or more cable rods 52, 53 (see two cable rods shown in FIG. 19) adjustably attached to vertical frame 12. Cable rod 52 may have a first end 54 and second end 56. First end 54 of the cable rod 52 may substantially extend away from vertical frame 12. In the particular embodiment illustrated, vertical frame 12 may have a substantially vertical orientation, being substantially perpendicular to a ground. In the particular embodiment illustrated, cable rod 52 may have a substantially horizontal orientation, and/or an orientation such that the cable rod is at an acute angle in relation to the ground. Thereby, cable rod 52 extends away from vertical frame 12. First end 54 of cable rod 52 may be configured to guide support cable 16 from automobile door 90, to where support cable 16 is connected to vertical frame 12 and/or tension means 50. Cable rod 52 may be adjustable vertically upon vertical frame 12, and may further be adjusted such that the distance between first end 54 of cable rod 52 and vertical frame 12 is increased and/or decreased. This adjustment for extension may occur through a series of positioning holes 58 on cable rod 52.

A cable guide 60 may be provided and attached to vertical frame 12. Cable guide 60 may be vertically adjustably upon vertical frame 12. The cable guide may be a screw extending substantially perpendicular to vertical frame 12, and may include a loop, hook, and/or similar shape that may guide a support cable 18.

A cable shield 62 may be provided and adjustably connected to vertical frame 12. Cable shield 62 may be plastic, metal, or similar material. Cable shield 62 may be positioned such that when door support hook 20 is engaged to automobile door 90 and support cables 16 and/or 18 extend from cable rod 52, support cables 16, 18 are shielded from door support frame 14 and similar parts of apparatus 10 that may obstruct the operation of the support cable.

Those skilled in the art would readily appreciate in view of this disclosure that various modifications may be made to automobile door support apparatus 10 without departing from the scope of the present invention. For example, in a particular embodiment, automobile door support apparatus 10 may extend from a ceiling mounted assembly. In this embodiment, vertical frame 12 may be connected to a ceiling mounted assembly, allowing for the apparatus to travel through an assembly conveyor with or without an automobile door attached thereon. Alternatively, automobile door support apparatus 10 may extend from a ground frame. In this embodiment, vertical frame 12 may be connected to a ground frame that is configured to contact the floor. The ground frame may be a stable frame and/or a mobile frame, i.e. a frame with wheels.

Based on the discussion above, automobile door support apparatus 10 is beneficial in that it allows for secure support of an automobile door 90 through the simple engagement of door support hook 20 and door support frame 14. Automobile door support apparatus 10, thereby allows for simplified use while consistently and securely supporting an automobile door.

Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. 

1. An automobile door support apparatus comprising: an apparatus support frame; a door support frame adjustably connected to said apparatus support frame, said door support frame having first and second support members, and an underside support member connected to said first and second support members; at least one underside brace connected to said underside support member and configured to support an underside of an automobile door; at least one cable rod having first and a second ends, said first end being configured to receive and maintain a support cable in a predetermined orientation and said second end being adjustably connected to one of said apparatus support frame and said door support frame, said support cable having first and second ends, said first end of said support cable being connected to a cable tension lever adjustably connected to said apparatus support frame for applying tension to said support cable and said second end of said support cable having a door support hook connected thereto, said door support hook being configured to removably engage a predetermined area of an automobile door, wherein actuation of said cable tension lever securely holds the automobile door via said support cable and said door support hook; and at least one upper door support adjustably connected to said apparatus support frame for supporting and maintaining the automobile door, wherein said automobile door support apparatus supports the automobile door in a predetermined position by contacting and supporting the door via said upper door support, said door support hook, and said underside brace.
 2. An apparatus according to claim 1, further comprising a cable guide adjustably attached to said apparatus support frame and configured to maintain said support cable in substantial alignment with said apparatus support frame.
 3. An apparatus according to claim 1, wherein said upper door support is rotatably connected to said apparatus support frame.
 4. An apparatus according to claim 1, wherein said upper door support further includes a plurality of door guides configured to contact automobile doors of different configurations.
 5. An apparatus according to claim 1, wherein said cable tension lever is a ratchet lever hoist.
 6. An automobile door support apparatus comprising: an apparatus support frame; a door support frame connected to said apparatus support frame, said door support frame configured to contact an automobile door at predetermined locations; at least one support cable adjustably connected to one of said apparatus support frame and said door support frame; and a door support hook connected to said support cable, said door support hook having a hook end and an cable end, wherein said hook end being configured to engage a predetermined area of the automobile door for securely supporting the automobile door on said automobile door support apparatus and disengage from said predetermined area to allow removal of the automobile door from said automobile door support apparatus.
 7. An apparatus according to claim 6, further comprising at least one cable rod adjustably attached to said apparatus support frame and having first and second ends, said first end of said cable rod extending away from said apparatus support frame and configured to guide said support cable.
 8. An apparatus according to claim 6, further comprising a tension means adjustably connected to said apparatus support frame and said support cable, said tension means being configured to place said support cable and said door support hook in tension upon actuation thereof.
 9. An apparatus according to claim 6, wherein said door support frame further includes an underside door support configured to support an underside of an automobile door.
 10. An apparatus according to claim 6, further comprising an upper door support adjustably attached to said door support frame, said upper door support being configured to contact an automobile door.
 11. An apparatus according to claim 6, wherein the apparatus support frame is configured to attach to and travel upon a ceiling mounted assembly track.
 12. An apparatus according to claim 6, further comprising a tensioning lever adjustably connected to said apparatus support frame and said support cable, said tension lever being configured to place said support cable and said door support hook in tension upon actuation thereof.
 13. A method for supporting an automobile door with an apparatus including an apparatus support frame, a door support frame connected to said apparatus support frame, said door support frame configured to contact an automobile door at predetermined locations, at least one support cable adjustably connected to said apparatus support frame, and a door support hook connected to said support cable, said door support hook having a hook end and an cable end, said method comprising: engaging said hook end to a predetermined area of the automobile door for securely supporting the automobile door on said automobile door support apparatus; and engaging a tensioning lever adjustably connected to said apparatus support frame and said support cable for placing said support cable and said door support hook in tension.
 14. A method according to claim 13, further comprising adjusting a connection of said apparatus support frame and said door frame support to align said door frame support with an automobile door.
 15. A method according to claim 13, wherein said predetermined area is a preformed keyhole.
 16. A method according to claim 13, further comprising disengaging said door support hook from said predetermined area for removing the automobile door from said apparatus. 